Handheld vacuum cleaner

ABSTRACT

A handheld vacuum cleaner includes a fluid flow path extending from a dirty air inlet to a clean air outlet, a main body including a handle, and a fluid flow motor positioned in the fluid flow path. The vacuum cleaner further includes a dirt collection region with an openable bottom and a cyclonic separator in the fluid flow-path. The cyclonic separator includes a cyclone chamber having a first end wall and a second end wall, a cyclone dirty fluid inlet, and a cyclone clean fluid outlet. The vacuum cleaner further includes a filter chamber in the fluid flow path downstream from the cyclonic separator and upstream from the fluid flow motor. The filter chamber includes an outlet fluidiy communicating the filter chamber and the fluid flow motor and a tangential inlet fluidiy communicating the cyclonic separator and the filter chamber.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to co-pending U.S. Provisional PatentApplication No. 62/253,508, filed on Nov. 10, 2015, the entire contentsof which are incorporated herein by reference.

BACKGROUND

The present invention relates to handheld vacuum cleaners, and moreparticularly, to cyclonic handheld vacuum cleaners.

SUMMARY

In one embodiment, the invention provides a vacuum cleaner including afluid flow path extending from a dirty air inlet to a clean air outlet,a main body including a handle, and a fluid flow motor positioned in thefluid flow path. The vacuum cleaner further includes a dirt collectionregion with an openable bottom and a cyclonic separator in the fluidflow path. The cyclonic separator includes a cyclone chamber having afirst end wall and a second end wall, a cyclone dirty fluid inlet, and acyclone clean fluid outlet. The vacuum cleaner further includes a filterchamber in the fluid flow path downstream from the cyclonic separatorand upstream from the fluid flow motor. The filter chamber includes anoutlet fluidly communicating the filter chamber and the fluid flow motorand a tangential inlet fluidly communicating the cyclonic separator andthe filter chamber.

In one embodiment, the invention provides a vacuum cleaner including afluid flow path extending from a dirty air inlet to a clean air outlet,a main body including a handle, and a fluid flow motor positioned in thefluid flow path. The vacuum cleaner further includes a cyclonicseparator in the fluid flow path. The cyclonic separator includes acyclone chamber having a first end wall, a second end wall, a sidewallextending along a cyclone axis, a cyclone dirty fluid inlet, and acyclone clean fluid outlet. The vacuum cleaner further includes a filterchamber housing a cylindrical filter in the fluid flow path downstreamfrom the cyclonic separator and upstream from the fluid flow motor. Anaxis defined by the cylindrical filter is transverse to the cycloneaxis.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a main body including a handle, and a fluid flow motorpositioned in the fluid flow path. The vacuum cleaner further includes acyclonic separator in the fluid flow path. The cyclonic separatorincludes a cyclone chamber having a first end wall, a second end wall, asidewall extending along a cyclone axis, a cyclone dirty fluid inlet,and a cyclone clean fluid outlet. The vacuum cleaner further includes afilter chamber in the fluid flow path downstream from the cyclonicseparator and upstream from the fluid flow motor, and an airflow passagebetween the cyclone clean fluid outlet and the filter chamber. Theairflow passage defines an upstream cross-sectional area and defines adownstream cross-sectional area. The downstream cross-sectional area islarger than the upstream cross-sectional area.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a fluid flow motor positioned in the fluid flow path, and acyclonic separator in the fluid flow path. The cyclonic separatorincludes a cyclone chamber having a first end wall and a second endwall, a cyclone dirty fluid inlet, and a cyclone clean fluid outlet. Thevacuum cleaner further includes a filter chamber in the fluid flow pathdownstream from the cyclonic separator and upstream from the fluid flowmotor. The filter chamber houses a pre-motor filter having a firstcylindrical filter and a second cylindrical filter. The secondcylindrical filter is nested within the first cylindrical filter.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a main body including a handle, and a fluid flow motorpositioned in the fluid flow path. The vacuum cleaner further includes acyclonic separator in the fluid flow path. The cyclonic separatorincludes a cyclone chamber having a first end wall, a second end wall, asidewall extending along a cyclone axis, a cyclone dirty fluid inlet,and a cyclone clean fluid outlet. The vacuum cleaner further includes afilter chamber housing a pre-motor filter in the fluid flow pathdownstream from the cyclonic separator and upstream from the fluid flowmotor. A gap between the pre-motor filter and an adjacent sidewall ofthe filter chamber is between 5 and 10 millimeters.

In another embodiment, the invention provide a handheld vacuum cleanerincluding a fluid flow path extending from a dirty air inlet o a cleanair outlet, a main body including a handle, and a fluid flow motorpositioned in the fluid flow path. The vacuum cleaner further includes acyclonic separator in the fluid flow path. The cyclonic separatorincludes a cyclone chamber having a first end wall and a second endwall, a cyclone dirty fluid inlet, and a cyclone clean fluid outlet. Thevacuum cleaner further includes a filter chamber housing a filter in thefluid flow path downstream from the cyclonic separator and upstream fromthe fluid flow motor. The filter chamber includes a lid removable toopen the filter chamber and the filter is coupled to the lid.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a fluid flow motor positioned in the fluid flow path, and acyclonic separator in the fluid flow path. The vacuum cleaner furtherincludes a filter chamber in the fluid flow path downstream from thecyclonic separator and upstream from the fluid flow motor. The filterchamber houses a pre-motor filter having a first stage filter and asecond stage filter. The first stage filter is removable from the secondstage filter.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a main body including a handle, and a fluid flow motorpositioned in the fluid flow path. The vacuum cleaner further includes acyclonic separator in the fluid flow path. The cyclonic separatorincludes a cyclone chamber having a first end wall and a second endwall, a cyclone dirty fluid inlet, and a cyclone clean fluid outlet. Thevacuum cleaner further includes a filter chamber in the fluid flow pathdownstream from the cyclonic separator and upstream from the fluid flowmotor. The filter chamber includes an inlet fluidly communicating thecyclonic separator and the filter chamber. The filter chamber includesan outlet fluidly communicating the filter chamber and the fluid flowmotor, and the inlet is perpendicular to the outlet.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a main body including a handle, and a fluid flow motorpositioned in the fluid flow path. The vacuum cleaner further includes acyclonic separator in the fluid flow path. The cyclonic separatorincludes a cyclone chamber having a first end wall and a second endwall, a cyclone dirty fluid inlet, and a cyclone clean fluid outlet. Thevacuum cleaner further includes a filter chamber in the fluid flow pathdownstream from the cyclonic separator and upstream from the fluid flowmotor. The filter chamber includes an inlet fluidly communicating thecyclonic separator and the filter chamber and an outlet fluidlycommunicating the filter chamber and the fluid flow motor. The inletincludes a rectangular cross-section and the outlet includes a circularcross-section.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a main body including a handle, and a fluid flow motorpositioned in the fluid flow path. The vacuum cleaner further includes acyclonic separator in the fluid flow path. The cyclonic separatorincludes a cyclone chamber having a first end wall, a second end wall, asidewall extending along a cyclone axis, a cyclone dirty fluid inlet,and a cyclone clean fluid outlet. The vacuum cleaner further includes afilter chamber in the fluid flow path downstream from the cyclonicseparator and upstream from the fluid flow motor. An axis defined by thefilter chamber is perpendicular to the cyclone axis.

In another embodiment, the invention provides a vacuum cleaner includinga fluid flow path extending from a dirty air inlet to a clean airoutlet, a main body including a handle, a fluid flow motor positioned inthe fluid flow path. The vacuum cleaner further includes a cyclonicseparator in the fluid flow path, and a filter chamber housing acylindrical filter in the fluid flow path downstream from the cyclonicseparator and upstream from the fluid flow motor. The filter chamberincludes a tangential inlet fluidly communicating the cyclonic separatorand the filter chamber. The fluid flow path extends through thecylindrical filter in a normal flow orientation.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a handheld vacuum cleaner according toan embodiment of the invention.

FIG. 2 is another perspective view of the handheld vacuum cleaner ofFIG. 1.

FIG. 3 is a bottom perspective view of the handheld vacuum cleaner ofFIG. 1.

FIG. 4 is a perspective view of a separator according to an embodimentof the invention.

FIG. 5 is another perspective view of the separator of FIG. 4.

FIG. 6 is a side view of the separator of FIG. 4.

FIG. 7 is a cross-sectional view of the separator of FIG. 4 taken alonglines 7-7 shown in FIG. 4.

FIG. 8 is another cross-sectional view of the separator of FIG. 4 takenalong lines 8-8 shown in FIG. 5.

FIG. 9 is another cross-sectional view of the separator of FIG. 4 takenalong lines 9-9 shown in FIG. 4.

FIG. 10 is another cross-sectional view of the separator of FIG. 4 takenalong lines 10-10 shown in FIG. 4.

FIG. 10A is a cross-sectional view of the separator of FIG. 4 takenalong lines 10A-10A shown in FIG. 10.

FIG. 11 is a partial perspective view of the cross-sectional view ofFIG. 10.

FIG. 12 is a perspective view of a filter assembly and a suction sourceaccording to an embodiment of the invention, with other componentsremoved for clarity.

FIG. 13 is an exploded view of the filter assembly of FIG. 12.

FIG. 13A is a perspective view of the filter assembly of FIG. 12 with apre-motor filter removed from a filter chamber.

FIG. 14 is a cross-sectional view of the filter assembly and suctionsource of FIG. 12 taken along lines 14-14 shown in FIG. 12.

FIG. 15 is a cross-sectional view of the filter assembly and motorassembly of FIG. 12 taken along lines 15-15 shown in FIG. 12,

FIG. 16 is a perspective view of a handheld vacuum cleaner according toanother embodiment of the invention.

FIG. 17 is a side view of the handheld vacuum cleaner of FIG. 16.

FIG. 18 is a perspective schematic view of the handheld vacuum cleanerof FIG. 16.

FIG. 19 is a perspective view of a separator according to an alternativeembodiment of the invention.

FIG. 20 is another perspective view of the separator of FIG. 19.

FIG. 21 is a perspective view of a cross-section of the separator ofFIG. 19 taken along lines 21-21 shown in FIG. 19.

FIG. 22 is another perspective view of the cross-section of theseparator of FIG. 19 taken along lines 21-21 shown in FIG. 19.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways.

DETAILED DESCRIPTION

FIGS. 1-15 illustrate a handheld vacuum cleaner 10. The handheld vacuumcleaner 10 includes a fluid flow path extending from a dirty air inlet14 formed in a suction nozzle 18 to a clean air outlet 22 (FIG. 1). Thehandheld vacuum cleaner 10 also includes a main body 26 (i.e., a mainhousing) with a handle 30, a front end 34, a hack end 38, a first side42, a second side 46, a bottom 50, and a top 54. The ditty air inlet 14and the suction nozzle 18 are located at the front end 34 of the mainbody 26. The handle 30 is located at the back end 38 and extendsgenerally in a top-to-bottom direction along the main body 26. In otherwords, the handle 30 is oriented generally vertical when the handheldvacuum cleaner 10 is sitting on a horizontal surface.

With reference to FIGS. 1-11, the handheld vacuum cleaner 10 includes acyclonic separator 58 and a dirt collection region 62. It is understoodthe cyclonic separator 58 is positioned in the fluid flow path and theassemblies illustrated in FIGS. 4-11 are utilized within the handheldvacuum cleaner 10 illustrated in FIGS. 1-3. In other words, FIGS. 4-11schematically illustrate certain details of the handheld vacuum cleaner10 with other components removed for clarity.

With reference to FIGS. 4-11, the cyclonic separator 58 includes acyclone chamber 66 (FIG. 7) having a first end wall 70, a second endwall 74, and a sidewall 78 extending between the first wall 70 and thesecond wall 74. The cyclonic separator 58 further includes a cyclonedirty fluid inlet 82 (FIG. 7), a cyclone clean fluid outlet 86, andcyclone dirt outlet 90 (FIG. 8). In the illustrated embodiment, thecyclone dirt outlet 90 is formed in the sidewall 78 proximal the secondend wall 74, the cyclone dirty fluid inlet 82 is formed in the sidewall78 proximate the first end wall 70, and the cyclone clean fluid outlet86 is formed in the first end wall 70.

With continued reference to FIG. 9, a flow-diverting wall 91 ispositioned adjacent the cyclone dirt outlet 90. The flow-diverting wall91 is positioned downstream from the cyclone dirt outlet 90 and debrisexiting the cyclone dirt outlet 90 travels past an upstream wall 92 andimpinges (i.e., impacts) the flow-diverting wall 91. This is a result ofthe airflow within the cyclonic separator moving in a generallyclockwise direction, as viewed from FIG. 9. The flow-diverting wall 91extends from the cyclone sidewall 78 between the cyclone chamber 66 andthe dirt collection region 62 in a direction along a cyclone chamberaxis 94 (FIG. 8). The flow-diverting wall 91 forms a downstream boundaryof the cyclone dirt outlet 90 and intersects the fluid flow pathadjacent the second end wall 74 between the cyclone chamber 66 and thedirt collection region 62. A duct 93 is famed in part by theflow-diverting wall 91 and the opposite wall 92 around the perimeter ofthe cyclone dirt, outlet 90 in fluid communication with the dirtcollection region 62. The flow-diverting wall 91 eliminates a common“knife-edge” formed in prior art designs between the edge of thematerial throw-off in cyclone sidewalls and the adjacent dust bin. Such“knife-edge” transitions in the prior art tended to catch debris flowingtoward it forming a debris clog point that reduced performance intraditional prior art cyclonic separator designs. In the embodimentshown in FIG. 9, debris exiting the cyclone dirt outlet 90 that passesover the wall 92 and impacts the flow-diverting wall 91 is at leastpartially guided toward the dirt collection region 62, which has beenfound to inhibit clogging of the cyclone dirt outlet 90.

The cyclone chamber axis 94 is defined by the sidewall 78 and passesthrough the first end wall 70 and the second end wall 74 (FIG. 8). Thefirst end wall 70 and the second end wall 74 of the cyclone chamber 66both intersect a common horizontal plane 98 (FIG. 6) when the handheldvacuum cleaner 10 is positioned on a horizontal surface. In other words,normally the cyclone chamber axis 94 is approximately horizontal whenthe handheld vacuum cleaner 10 is in use. As used in the presentdescription and claims, an approximately or generally horizontalorientation means an orientation that is tilted over such that it is notvertical or upright. The generally horizontal orientation includesvarious embodiments that are approximately parallel to the ground orfloor, as well as orientations that are not parallel to the ground orfloor but being generally more laying over than upright (i.e., beingtilted more than about 45 degrees). For example, a horizontalorientation can include a cyclonic separator having a portion of a firstend and a portion of a second end both intersecting a common horizontalplane.

With reference to FIGS. 10 and 11, the cyclonic separator 58 furtherincludes a ramp 102 positioned in the cyclone chamber 66 around at leasta portion of the second end wall 74 extending along the sidewall 78toward the cyclone dirt outlet 90. In particular, the ramp 102 includesa beginning 106 spaced from the second end wall 74, and the ramp 102includes an end 110 positioned at the second end wall 74 of the cyclonechamber 66. In the illustrated embodiment, a portion of the ramp surface102 as viewed in a plane parallel to and through the cyclone chamberaxis 94 is approximately perpendicular to the sidewall 78, shown asangle θ in FIG. 10A. Alternatively, the ramp surface angle θ may be at anon-perpendicular angle from the sidewall between about 30 degrees and150 degrees. In yet another alternative, the ramp surface angle θ may beat a non-perpendicular angle from the sidewall between about 60 degreesand 120 degrees.

The ramp 102 is positioned such that the ramp end 110 positioned at thesecond end wall is along a flow path directed toward the cyclone dirtoutlet 90 and the flow-diverting wall 91. In the illustrated embodiment,the ramp 102 is a helical ramp. The ramp 102 shown in FIG. 11 extendsaround an upper portion 114 of the sidewall 78; however, the ramp may bearranged along a middle portion or lower portion of the sidewall inembodiments having the cyclone dirt outlet in a different location thanin the present embodiment. In the illustrated embodiment, the ramp 102extends around approximately 180 degrees around the sidewall 78 (i.e.,approximately half). In alternative embodiments, the ramp can extendaround more or less of the perimeter of the cyclone to guide debrisalong a flow path directed toward the cyclone dirt outlet. The ramp mayextend between about 90 degrees and 300 degrees around the cycloneperimeter. The ramp 102 guides debris in the cyclone chamber 66 to thecyclone dirt outlet 90. In addition, the ramp 102 inhibits the mixing ofany air flow out of the cyclone through the dirt outlet withcorresponding air flow in the cyclone across the cyclone dirt outlet 90,which in turn minimizes the re-entrainment of debris.

With reference to FIGS. 7 and 8, the cyclonic separator 58 furtherincludes a shroud 115 positioned around a portion of the cyclone cleanfluid outlet 86 configured to allow airflow from the cyclonic separator58 to pass through the shroud 115 into the clean fluid outlet 86 andinhibiting passage of debris into the clean fluid outlet 86. In theillustrated embodiment, the shroud 115 includes a conical frame 116 witha mesh 117. The conical frame 116 and the mesh 117 provides more volumebetween the conical frame 116 and the sidewall 78 at the smaller end ofthe conical frame 116. The tangential flow of the swirling air anddebris within the cyclonic separator 58 washes against the mesh 117while the axial component of the flow pushes the debris toward thesmaller end of the conical frame 116, which helps clear debris from theshroud 115 back into the separator flow. As such, a self-cleaning effectis achieved with the shroud 115 as debris is carried along with theflow, slowing the “wrapping” of debris in the cyclone chamber 66 aroundthe shroud 115. Reducing the wrapping of debris inhibits clogging of theseparator that formed in some prior art designs. In some embodiments,the shroud 115 and the first end wall 70 of the cyclonic separator 58may be removable by a user from the first side 42 of the main body 26 toallow a user access to the cyclone chamber 66.

With reference to FIGS. 5-7, the handheld vacuum cleaner 10 furtherincludes an outlet scroll 118 in fluid communication with the cycloneclean fluid outlet 86. The outlet scroll 118 includes a central portion122 forming an end of the clean fluid outlet 86 and an airflow passage126 downstream of the central portion 122. The outlet scroll 118 isconfigured to change the airflow path from a generally helical airflowalong a first direction through the clean fluid outlet 86 to an airflowhaving less rotation along a second direction different than the firstdirection along the airflow passage 126 downstream of the central potion122. In the illustrated embodiment, the first direction is along a firstaxis defined by the clean fluid outlet 86, and the second direction isalong a second axis defined by the airflow passage 126 downstream of thecentral portion 122, where the second axis is transverse to the firstaxis. In other words, the outlet scroll 118 tends to straighten the flowas it passes from the cyclone clean fluid outlet 86 to the airflowpassage 126. The airflow passage 126 is generally tangentially alignedwith the central portion 122. In the illustrated embodiment, the centralportion 122 is generally cylindrical having a dimension larger than adimension of the airflow passage, the airflow passage 126 being radiallyoffset in the central portion 122 in the direction of the airflow suchthat the airflow has a tangential exit from the central portion 122 intothe airflow passage 126. More specifically, the airflow passage 126defines a central longitudinal axis 130 that does not intersect amidpoint 134 of the central portion 122. The outlet scroll 118 is morecompact than a 90-degree elbow that was required in prior designs tochange direction from the center axis of the separator to the directiontoward the filter assembly. In addition, the outlet scroll 118 convertsthe swirling flow along the clean fluid outlet 86 into a morestraightened flow along the airflow passage 126, which retains some ofthe kinetic energy that would otherwise be lost in a 90-degree elbow,resulting in a lower pressure drop. In other words, as a result of thepassage 126 being tangentially aligned with the central portion 122 inthe airflow direction, clean air entering the central portion 122 fromthe cyclone clean fluid outlet 86 leaves the central portion 122 with alower pressure drop when compared to traditional elbow turns.

With reference to FIGS. 1-3 and 8-10, the dirt collection region 62(i.e., dirt collection chamber) is removably secured to the main body 26and in fluid communication with the cyclone dirt outlet 90 of thecyclonic separator 58. The dirt collection region 62 includes anopenable bottom door 138 on the bottom of the dirt collection region 62,which allows for emptying the dirt collection region 62. In theillustrated embodiment, the bottom door 138 is released by actuation ofa catch 139 (FIG. 2), or other suitable releasable securing means. Thedirt collection region 62 is at least partially defined by a transparentbin 142 that is removably secured to the main body 26 via a catch 146(FIG. 1), or other suitable releasable securing means. In theillustrated embodiment, the bin 142 is both removable from the main body26 and the bottom door 138 is openable. As such, the bottom of the dirtcollection region 62 is openable when the bin 142 is removed from themain body 26 or attached to the main body 26. The dirt collection region62 includes ribs 150 to deflect the flow of air and inhibit the debriscontained in the dirt collection region 62 from becoming re-entrained inthe airflow.

With reference to FIGS. 12 and 15, the handheld vacuum cleaner 10further includes a suction source 154 positioned in the fluid flow path.The suction source 154 is located in the main body 26 and includes afluid flow motor 158 (FIG. 15) and a fan operable to generate a fluidflow path (i.e., a suction airflow) through the handheld vacuum cleaner10 that is drawn from the dirty air inlet 14 through the cyclonicseparator 58 to a motor air outlet 20, which is ducted to the clean airoutlet 22 (FIG. 1). The motor 158 defines a motor axis 162 and the motor158 is operable to rotate the fan about the motor axis 162. In theillustrated embodiment, the motor 158 and the fan are oriented such thatthe motor axis 162 extends in a direction toward the bottom 50 and thetop 54 of the main body 26 and therefore, the motor axis 162 isgenerally vertical when the vacuum is positioned on a horizontalsurface. In other words, the fluid flow motor axis 162 of the fluid flowmotor 158 is approximately vertical when the handheld vacuum cleaner 10is positioned on a horizontal surface. The fluid flow motor axis 162 ispositioned closer to the handle 30 than the cyclone chamber axis 94 isto the handle 30. The fluid flow motor axis 162 is offset from andapproximately perpendicular to the cyclone chamber axis 94.

With reference to FIGS. 1-3, the handheld vacuum cleaner 10 includes abattery 168 (i.e., a removable, rechargeable battery pack) to supplypower to the suction source 154 to operate the motor 158 and otherelectrical components. The battery 168 is positioned at least partiallybelow the bottom openable door 138 of the dirt collection region 62.When the battery 168 is attached to the main body 26, the handheldvacuum cleaner 10 is supported solely on the battery 168 when positionedon the horizontal surface. In other words, the battery 168 provides abottom surface 172 that allows the entire handheld vacuum cleaner 10 tobe supported by the battery 168 when the handheld vacuum cleaner ispositioned on a horizontal surface.

With reference to FIGS. 12-15, the handheld vacuum cleaner 10 furtherincludes a filter assembly 175 having a pre-motor filter 176 and afilter chamber 180. The pre-motor filter assembly 175 is located in themain body 26 with the filter chamber 180 positioned above the motor 158.The pre-motor filter 176 and the filter chamber 180 are in the fluidflow path downstream from the cyclonic separator 58 and are upstreamfrom the fluid flow motor 158. The pre-motor filter 176 and filterchamber 180 are positioned between the handle 30 and the cyclonicseparator 58. The pre-motor filter 176 filters the fluid flow pathbefore the air travels through the fan and the motor 158. With referenceto FIG. 13, the pre-motor filter 176 has a first cylindrical filter 184,optionally a second cylindrical filter 188, and a filter frame 192. Thesecond cylindrical filter 188 is nested within and removable from thefirst cylindrical filter 184, and both filters 184, 188 are positionedaround the filter frame 192. In the illustrated embodiment, the firstcylindrical filter 184 defines an inner diameter 189 (FIG. 13) and thesecond cylindrical filter 188 defines an outer diameter 190, and theinner diameter 189 and the outer diameter 190 are approximately equal(e.g., within approximately 1 mm, 5 mm, 10 mm, etc. of each other). Insome embodiments, the inner diameter 189 of the first cylindrical filter184 is smaller than the outer diameter 190 of the second cylindricalfilter 188 such that the second cylindrical filter 188 is slightlycompressed (i.e. deformed) in order to be nested within the firstcylindrical filter 184 in a press-fit type configuration, in alternativeembodiments, there exists a gap radially between the first cylindricalfilter 184 and the second cylindrical filter 188.

The filter frame may be integral with one of the first or secondcylindrical filters, and for some embodiments the filter frame isomitted. In the illustrated embodiment, the second cylindrical filter188 is configured to remove finer particles from the airflow than thefirst cylindrical filter 184 and the combination of the first and secondcylindrical filters provides desired filtration of the airflow. Inalternative embodiments, the first cylindrical filter 184 providesdesired filtration of the airflow and the second cylindrical filter 188is omitted. The first cylindrical filter 184 and second cylindricalfilter 188 may be any desired filter media, including pleated ornon-pleated, non-woven fiber, foam, or other media. The pre-motor filter176 defines a filter axis 196 that is co-axial with the fluid flow motoraxis 162 when the pre-motor filter 176 is assembled within the filterchamber 180. In addition, the filter axis 196 is transverse to thecyclone axis 94. In the illustrated embodiment, the filter axis 196defined by the cylindrical pre-motor filter 176 is perpendicular to thecyclone chamber axis 94. In alternative embodiments, the pre-motorfilter assembly 175 may be positioned such that the filter axis 196 isoffset from and parallel to the motor axis.

With reference to FIGS. 12-14, the filter chamber 180 includes atangential inlet 200 fluidly communicating the cyclonic separator 58 andthe filter chamber 180, in particular, the airflow passage 126 extendsbetween the cyclone clean fluid outlet 86 (more specifically, the outletscroll 118) and the tangential inlet 200. The passage 126 endsdownstream with the tangential inlet 200 to the filter chamber 180, thetangential inlet 200 providing a smooth airflow transition into thefilter chamber 180 reducing the velocity of the airflow into thepre-motor filter 176. More specifically, the inlet 200 to the filterchamber 180 shown in FIG. 14 is a scroll inlet. The airflow passage 126is positioned providing an entry 201 to the scroll inlet 200 adjacentthe filter chamber 180. The scroll inlet 200 is an arcuate passage froman entry 201 to a tangential entry 202 to the filter chamber 180. Thetangential entry 202 to the filter chamber 180 may be between 90 and 360degrees from the entry 201 to the scroll inlet 200, shown as angle β inFIG. 14. In other words, the filter chamber 180 includes a scroll inlet200 having a tangential inlet 202 to the filter chamber 180 between 90and 360 degrees from entry 201 of the scroll inlet 200. In someembodiments, part or all of the passage 126 and the outlet scroll 118are openable to allow a user access to the same.

With continued reference to FIGS. 13-15, the filter chamber 180 alsoincludes an outlet 203 fluidly communicating the filter chamber 180 andthe fluid flow motor 158. In the illustrated embodiment, the outlet 203is perpendicular to the tangential inlet 200. For example, with thevacuum cleaner 10 positioned on a horizontal surface, the fluid flowenters the tangential inlet 200 generally horizontal and leaves theoutlet 203 generally vertically (i.e., the fluid flow makesapproximately a 90 degree turn in the filter chamber 180). The fluidflow path extends through the cylindrical filters 184, 188 in a normalflow orientation (i.e., the fluid flow move radially inwards toward thecenter of the cylindrical filters 184, 188). In some embodiments, theinlet 200 includes a rectangular cross-section shape and the outlet 203includes a circular cross-section shape.

With reference to FIGS. 12 and 13, the filter chamber 180 is openablefrom the top 54 of the main body 26 when the handheld vacuum cleaner 10is positioned on a horizontal surface. In particular, a removable lid204 is provided on the top of the filter chamber 180 that may be openedby a user. As such, the pre-motor filter 176 is removably, from the topof the filter chamber 180 through the top 54 of the main body 26. Insome embodiments, the pre-motor filter 176 is attached to the lid 204such that the lid acts as a handle to lift the filter out of the filterchamber. In some embodiments, the first cylindrical filter 184 iscoupled to the removable lid 204 and the first cylindrical filter 184 isremoved with the lid 204 by a user, leaving the second cylindricalfilter 188 behind in the filter chamber 180. Alternatively oradditionally, the filter frame 192 is attached to or integral with thelid 204 as shown in FIG. 13A.

The pre-motor filter 176 is positioned in the filter chamber 180. Thefilter chamber 180 is configured to provide a gap 181 (FIGS. 14 and 15)between the pre-motor filter 176 and an adjacent sidewall 182 of thefilter chamber 180 between 5 and 10 millimeters. In one alternative, thegap 181 between the pre-motor filter 176 and adjacent sidewall 182 ofthe filter chamber 180 is between 5 and 8 millimeters. In anotheralternative, the gap 181 between the pre-motor filter 176 and adjacentsidewall 182 of the filter chamber 180 is between 8 and 10 millimeters.In other embodiments, the gap 181 between the pre-motor filter 176 andthe adjacent sidewall 182 of the filter chamber 180 is larger than 5millimeters to provide the desired airflow around the filter.

The airflow passage 126 extends in a lengthwise direction between thecyclonic separator 58 and the filter chamber 180, and has a height 124and a width 125. As shown in FIG. 13A, the height 124 of the airflowpassage 126 may increase along the downstream direction to slow thevelocity of the air passing through the passage 126. Alternatively oradditionally, the width 125 of the airflow passage 126 may increasealong the downstream direction. In other words, with reference to FIG.13A, the airflow passage 126 defines an upstream cross-sectional area127 and defines a downstream cross-sectional area 128, and thedownstream cross-sectional area 128 is larger than the upstreamcross-sectional area 127 (i.e., the airflow passage 126 increases involume along the downstream direction).

With reference to FIGS. 1-15, the handheld vacuum cleaner 10 includes alayout including the dirt collection region 62 generally located belowthe cyclonic separator 58 and adjacent the battery 168 and the suctionsource 154. The battery 168 is positioned below the fluid flow motor158. In the embodiment illustrated in FIGS. 1-2, the battery 168 isentirely positioned below the fluid flow motor 158. The fluid flow motor158 is positioned between the dirt collection region 62 and the handle30. The filter chamber 180 is positioned above the fluid flow motor 158when the handheld vacuum cleaner 10 is positioned on a horizontalsurface. Furthermore, the filter chamber 180 defines a filter chamberaxis 208 that is coaxial with the fluid flow motor axis 162 and thefilter axis 196. In alternative embodiments, the filter chamber axis 208is offset from and parallel to the fluid flow motor axis 162. In theillustrated embodiment, the filter chamber axis 208 is perpendicular tothe cyclone chamber axis 94. The filter chamber 180 and the fluid flowmotor 158 are both positioned between the cyclonic separator 58 and thehandle 30.

In operation, the battery 168 provides power to the motor 158 to rotatethe fan to generate a suction airflow that is drawn through the suctionnozzle 18 along with debris. The airflow, entrained with debris, travelsto cyclone dirty fluid inlet 82 of the cyclonic separator 58. Theairflow and debris travel into the cyclone chamber 66 where the airflowand debris rotate about the cyclone chamber axis 94. Rotation of theairflow and debris causes the debris to separate from the airflow andthe debris is discharged through the cyclone dirt outlet 90. The ramp102 aids in expelling the separated debris out the cyclone dirt outlet90. The separated debris then falls into the dirt collection region 62.The clean air travels through the shroud 115 into the cyclone cleanfluid outlet 86. The clean airflow then travels through the outletscroll 118 and is routed to the tangential inlet 200 of the filterchamber 180. The airflow then travels through the pre-motor filter 176before traveling through the suction source 154. After traveling throughthe suction source 154, the airflow is exhausted from the handheldvacuum cleaner 10 through exhaust openings in the main body 26.

After using the handheld vacuum cleaner 10, the user can open the door138 to empty the dirt collection region 62. After several uses debrismay have collected on the shroud 115 and within the cyclone chamber 66.If so, the user can open or remove a portion of the first end wall 70and outlet scroll 118 to remove the shroud 115 from the cyclonicseparator 58. This allows the user to clean the shroud 115 and insidethe sidewall 78. In addition, opening the removable lid 204 provides theuser access to the filter chamber 180 and the pre-motor filter 176 sothe user can clean or replace the pre-motor filter 176.

With reference to FIGS. 16-18, an alternative handheld vacuum cleaner310 is illustrated. The alternative handheld vacuum cleaner 310 issimilar to and includes many of the same components as the handheldvacuum cleaner 10 illustrated in FIGS. 1-15. As such, like componentsare reference the same with only the differences described in detailbelow. Similar to the handheld vacuum cleaner 10, the handheld vacuumcleaner 310 includes a fluid flow path extending from a dirty air inlet14 formed in a suction nozzle 18 to a clean air outlet. The handheldvacuum cleaner 310 also includes a main body 26 with a handle 30, and afluid flow motor 158 (FIG. 18) and a cyclonic separator 358 positionedin the fluid flow path.

The cyclonic separator 358 includes a cyclone chamber 366 having a firstend wall 370, a second end wall 374, and a sidewall 378 extendingbetween the first end wall 370 and the second end wall 374. The cyclonicseparator 358 further includes a cyclone dirty fluid inlet 382, acyclone clean fluid outlet 386, and a cyclone dirt outlet 390. A cyclonechamber axis 394 (FIG. 16) passes through the first end wall 370 and thesecond end wall 374. The first end wall 370 and the second end wall 374of the cyclone chamber 366 both intersect a common horizontal plane 398when the handheld vacuum cleaner 310 is positioned on a horizontalsurface. In other words, normally the cyclone chamber axis 394 isapproximately horizontal when the handheld vacuum cleaner 310 is in use.

A debris deceleration chamber 380 is positioned between the cyclonechamber 366 and a dirt collection region 362. The debris decelerationchamber 380 is in fluid communication with the cyclonic separator 358and the dirt collection region 362. In particular, the debrisdeceleration chamber 380 is in fluid communication with the cyclone dirtoutlet 390. In the illustrated embodiment, the debris decelerationchamber 380 is conical or funnel shaped defining a deceleration chamberaxis 385 that is transverse to the cyclone axis 394. In the illustratedembodiment, the chamber axis 385 is approximately perpendicular to thecyclone axis 394. The debris deceleration chamber 380 includes an inlet381 that is larger in cross-sectional area than an outlet 383. Theoutlet 383 of the debris deceleration chamber 380 is in fluidcommunication with the dirt collection region 362. Dirt exiting thecyclone dirt outlet 390 having a general flow direction around thecyclone axis 394 enters the debris deceleration chamber 380 which turnsthe flow in a direction around the chamber axis 385 where the velocityof the dirt is decreased before entering the dirt collection region 362.The slower debris speed created by the debris deceleration chamber 380helps prevent debris in the dirt collection region 362 from becomingre-entrained in the fluid flow path. The debris deceleration chamber 380defines the axis 385 (FIG. 17) that passes through the inlet 381 and theoutlet 383. The axis 385 is generally askew and is neither orientedvertically nor horizontally. In the illustrated embodiment, the axis isapproximately 30 degrees from vertical.

With reference to FIG. 17, the dirt collection region 362 includes anopenable bottom door 438. The door 438 is openable while the handheldvacuum cleaner 310 is supported solely on a battery 168. In other words,a bottom surface 172 of the battery 168 is below the openable door 438.With reference to FIG. 18, the handheld vacuum cleaner 310 furtherincludes a filter chamber 180 with a tangential inlet 200. The filterchamber 180 defines a filter chamber axis 208 that is coaxial with amotor axis 162 of a motor 158.

With reference to FIGS. 19-22, an alternative cyclonic separator 558 isillustrated. The alternative cyclonic separator 558 is similar to andincludes many of the same components as the cyclonic separator 58illustrated in FIGS. 4-11 As such, like components are referenced thesame with only the differences described in detail below. It isunderstood that the cyclonic separator 558 can be implemented in eitherof the handheld vacuum cleaners 10, 310 described above. Similar to thecyclonic separator 58, the cyclonic separator 558 is positioned in thefluid flow path.

The cyclonic separator 558 includes a cyclone chamber 566 having a firstend wall 570, a second end wall 574, and a sidewall 578 extending alonga cyclone axis 594 between the first end wall 570 and the second endwall 574. The cyclonic separator 558 further includes a cyclone dirtfluid inlet 582, a cyclone clean fluid outlet, and a cyclone dirt outlet590 formed in the sidewall 578. The cyclone chamber axis 594 passesthrough the first end wall 570 and the second end wall 574. The firstend wall 570 and the second end wall 574 of the cyclone chamber 566 bothintersect a common horizontal plane when the handheld vacuum cleaner ispositioned on a horizontal surface. In other words, normally the cyclonechamber axis 594 is approximately horizontal when the handheld vacuumcleaner is in use.

With reference to FIGS. 21 and 22, the second end wall 574 includes aninner portion 575 and an outer portion 576. The outer portion 576 isoffset from the inner portion 575 in a direction away from the first endwall 570. A flow-diverting wall 591 connects the inner portion 575 andthe outer portion 576 of the second end wall 574, which bounds thedownstream end of the cyclone dirt outlet 590. In other words, theflow-diverting wall 591 forms a downstream boundary of the cyclone dirtoutlet 590, and the flow-diverting wall 591 is positioned along thedirection of the cyclone axis 594. The flow-diverting wall 591intersects the fluid flow path adjacent the second end wall 574 and ispositioned between the cyclone chamber 566 and a dirt collection region562. The flow-diverting wall 591 is positioned downstream from thecyclone dirt outlet 590 and debris exiting the cyclone dirt outlet 590impinges (i.e., impacts) the flow-diverting wall 591 while the samedebris exiting the cyclone dirt outlet 590 travels over an opposite wall592. A duct 593 is at least partially formed by the flow-diverting wall591, the opposite wall 592, and the second end wall 574. The duct 593 isin fluid communication with the cyclone dirt outlet 590 and the dirtcollection region 562. Similar to the flow-diverting wall 91 describedabove, the flow-diverting wall 591 eliminates a common “knife-edge”formed in prior art designs between the edge of the material throw-offin cyclone sidewalls and the adjacent dust bin. Such “knife-edge”transitions in the prior art tended to catch debris flowing toward itforming a debris clog point that reduced performance in traditionalprior art cyclonic separator designs. In the illustrated embodiment, theflow-diverting wall 591 is larger in cross-sectional area than theopposite wall 592. In addition, the inner portion 575 is similar to theramp 102 described above since the inner portion 575 includes abeginning 606 spaced from the outer portion 576 and an end 610positioned at the outer portion 576 of the second end wall 574.

Although the separators 58, 358, and 558 described above were detailedas cyclonic, over-the-wall type separators, other alternative cyclonicand non-cyclonic separators are considered. In particular, the cyclonicseparator can be, in alternative embodiments: a bag filtering unit; aconical separator; etc.

Various features and advantages of the invention are set forth in thefollowing claims.

1.-15. (canceled)
 16. A vacuum cleaner comprising: a fluid flow pathextending from a dirty air inlet to a clean air outlet; a main body; afluid flow motor positioned in the fluid flow path; a dirt collectionchamber; a cyclonic separator in the fluid flow path, the cyclonicseparator including a cyclone chamber having a first end and a secondend, a cyclone dirty fluid inlet, and a cyclone clean fluid outlet; anda filter chamber and a filter in the fluid flow path downstream from thecyclonic separator and upstream from the fluid flow motor; wherein thefilter chamber includes an outlet fluidly communicating the filterchamber and the fluid flow motor and a tangential inlet fluidlycommunicating the cyclonic separator and the filter chamber.
 17. Thevacuum cleaner of claim 16, the filter including a cylindrical filter.18. The vacuum cleaner of claim 17, wherein the fluid flow path extendsthrough the cylindrical filter in a normal flow orientation.
 19. Thevacuum cleaner of claim 17, wherein the filter includes a firstcylindrical filter and a second cylindrical filter, the secondcylindrical filter being nested within the first cylindrical filter. 20.The vacuum cleaner of claim 17, further comprising a gap between thecylindrical filter and an adjacent sidewall of the filter chamber, thegap being in a range from 5 to 10 millimeters.
 21. The vacuum cleaner ofclaim 16, wherein the fluid flow path through the filter chamber outletis perpendicular to the fluid flow path through the filter chamberinlet.
 22. The vacuum cleaner of claim 16, wherein filter chamber outletincludes a circular cross-section and the filter chamber inlet includesa rectangular cross-section.
 23. The vacuum cleaner of claim 16, whereinthe filter chamber includes a scroll inlet having the tangential inletto the filter chamber between 90 and 360 degrees from entry of thescroll inlet.
 24. The vacuum cleaner of claim 16, wherein the filterchamber includes a lid removable to open the filter chamber, and whereinthe filter is coupled to the lid.
 25. The vacuum cleaner of claim 16,wherein the fluid flow motor defines a fluid flow motor axis that isvertical when the vacuum cleaner is positioned on a horizontal surface.26. The vacuum cleaner of claim 25, wherein the filter chamber defines afilter chamber axis that is coaxial with the fluid flow motor axis. 27.The vacuum cleaner of claim 16, wherein the fluid flow motor defines afluid flow motor axis and the filter chamber defines a filter chamberaxis that is coaxial with the fluid flow motor axis.
 28. A vacuumcleaner comprising: a fluid flow path extending from a dirty air inletto a clean air outlet; a main body; a fluid flow motor positioned in thefluid flow path; a dirt collection chamber; a cyclonic separator in thefluid flow path, the cyclonic separator including, a cyclone chamberhaving a first end and a second end, a cyclone dirty fluid inlet, and acyclone clean fluid outlet; and a ramp in the cyclone chamber extendingalong a sidewall toward the cyclone dirt outlet; and wherein a beginningof the ramp is spaced from the second end wall and an end of the ramp ispositioned at the second end wall of the cyclone chamber.
 29. The vacuumcleaner of claim 28, wherein the first end wall and the second end wallof the cyclone chamber both intersect a common horizontal plane when thevacuum cleaner is positioned on a horizontal surface.
 30. The vacuumcleaner of claim 28, further comprising: a downstream duct connected tothe cyclone clean fluid outlet in the fluid flow path between thecyclonic separator and the motor; and an outlet scroll between thecyclone clean fluid outlet and the downstream duct; wherein the fluidflow path along the cyclone clean fluid outlet is along a firstdirection and the fluid flow path along the downstream duct is along asecond direction different than the first direction.
 31. A vacuumcleaner comprising: a fluid flow path extending from a dirty air inletto a clean air outlet; a main body; a fluid flow motor positioned in thefluid flow path; a dirt collection chamber; a cyclonic separator in thefluid flow path, the cyclonic separator including, a cyclone chamberhaving a first end and a second end, a cyclone dirty fluid inlet, and acyclone clean fluid outlet; and a downstream duct connected to thecyclone clean fluid outlet in the fluid flow path between the cyclonicseparator and the motor; and an outlet scroll between the cyclone cleanfluid outlet and the downstream duct; wherein the fluid flow path alongthe cyclone clean fluid outlet is along a first direction and the fluidflow path along the downstream duct is along a second directiondifferent than the first direction.
 32. The vacuum cleaner of claim 31,wherein the outlet scroll is configured to change the airflow path froma generally helical airflow along the first direction through the cleanfluid outlet to an airflow having less rotation along the seconddirection through the downstream duct.
 33. The vacuum cleaner of claim31, wherein the first direction is perpendicular to the seconddirection.